Form for casting a concrete light pole base

ABSTRACT

A process and form for casting a concrete light pole base having a decorative upper portion with a configuration for mounting a light pole. The form includes a base having an opening in which a resilient insert is positioned. The insert has openings for holding threaded ends of mounting bolts and for positioning wiring conduits. Ends of the bolts extend from the insert into the mold cavity. Different inserts may be used to accommodate different light pole mounting specifications. A first form section for shaping a decorative upper portion of the light pole base is positioned on the base, and forms for shaping the cylindrical lower end of the light pole base are secured above the first form section.

CLAIM OF PRIORITY

This patent application is a divisional application of U.S. patentapplication Ser. No. 14/210,613 and claims priority to and the benefitof the filing date thereof.

FIELD

The invention relates to cast concrete products and specifically to aprocess and a form for casting a concrete light pole base suitable formounting a light pole of the type used, for example, in parking lots andfor highway lighting.

BACKGROUND

Tall light poles are used, for example, for parking lot lighting and forhighway lighting. The lower end of a light pole has a pattern of holesfor receiving bolts which are embedded in a concrete base. The layoutand spacing of the holes, hole diameters and number of holes can varybetween lighting pole manufacturers and between different size anddifferent model poles made by the same manufacturer. Concrete light polebases are typically a cylindrical concrete column having a roundexterior and a flat top from which the threaded ends of embedded boltsextend. The number, size and spacings of the bolts are determined by thehole pattern in the base of the light pole which will be mounted on thebase. One or more conduits are embedded in the concrete base for feedingunderground wiring to a light fixture mounted on the light pole. Theheight of the pole base is based on the size of the light pole and thelight fixtures mounted on the pole to provide the necessary stabilityfor the light pole, and to the height the base is to extend aboveground. In parking lots, for example, it may be desirable to have thebase extend sufficiently above ground to prevent vehicle damage to thelight pole.

The specification for a light pole base bolt pattern are based on thebase configuration of a specific light pole which will be mounted on thebase. A hole is drilled into the ground for receiving the light polebase. The diameter of the hole is based on the diameter of the base andthe depth of the hole is determined by the total length of the base lessthe amount that the base is to extend above the ground surface. Thelight pole is bolted to the base and electrical wires extend through oneor more conduits in the base and up through the light pole for poweringlighting fixtures which will be attached to the pole. The minimumdimensions of the portion of the base which will be embedded in theground will be influenced by the size of the pole to be mounted on thebase and the properties of the soil in which the base is buried.

The portion of a typical concrete pole base which extends above theground has been an extension of the round cylinder which is embedded inthe ground. From an architectural point of view, it is unattractive.

BRIEF SUMMARY OF THE INVENTION

The invention is directed to a form and process for casting concretelight pole bases in which the portion of the base which will extendabove the ground may be shaped to simulate a desired decorativeappearance such as simulating stacked stone blocks, a ribbed appearanceor to provide another desired appearance. The form facilitates providingdifferent bolt patterns for mounting different configured light poles onthe cast base and for positioning wiring conduits to align with a lightpole mounted on the base.

Various objects and advantages of the invention will become apparentfrom the following detailed description of the invention and theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a fragmentary perspective view of a portion of a cylindricalprior art concrete light pole base which extends above the ground and aportion of a light pole secured to the base;

FIG. 2 is a perspective view of one half section of a prior art formused to cast the concrete light pole base of FIG. 1;

FIG. 3 is a perspective side view as seen from the lower end of aconcrete light pole base made using a form according to the invention;

FIG. 4 is a fragmentary perspective view of the lower end of the lightpole base of FIG. 3 showing details of a lifting hook embedded in theconcrete light pole base;

FIG. 5 is a perspective view of the top of a concrete light pole baselaying on its side which was formed according to the invention andshowing a first exemplary pattern of mounting bolts and wiring conduitopenings;

FIG. 6 is a perspective view of the top of a concrete light pole baselaying on its side which was formed according to the invention andshowing a second exemplary pattern of mounting bolts and wiring conduitopenings;

FIG. 7 is a perspective view of an open form according to the inventionin which the above ground portion of a concrete light pole base is cast;

FIG. 8 is a perspective view of a base plate which supports the form inwhich the above ground portion of a concrete light pole base is cast andshowing an insert for positioning the light pole mounting bolts andwiring conduits;

FIG. 9 is a fragmentary side view of a portion of an insert showing abushing securing an end of a wiring conduit to the insert;

FIG. 10 is a perspective view of a base plate which supports the form inwhich the above ground portion of a concrete light pole base is cast andshowing modified inserts for positioning the light pole mounting boltsand wiring conduits; and

FIG. 11 is a further modified insert on a base plate for positioninglight pole mounting bolts and wiring conduits.

DETAILED DESCRIPTION OF THE INVENTION

Referring to the drawings, FIG. 1 shows a fragmentary portion of a priorart cast concrete light pole base 15 and an attached lower end of alight pole 16. The light pole base 15 is cylindrical in shape and has alower portion 17 which is buried in the ground and an upper portion 18which may be located close to the ground surface 19 or extend above theground surface 19, as shown. When the light pole base 15 is located in asurface parking lot, it is typically installed with the upper portion 18extending a sufficient distance above the ground surface 19 to protectthe light pole 16 from vehicle damage. The dimensions of the light polebase are designed to provide stability for the light pole 16 which willbe mounted on the base 15. Various factors including the height, weightand wind resistance of the light pole and lighting fixtures mounted onthe pole, and the properties of the ground in which the light pole basewill be installed are considered in determining the diameter of the base15 and the depth that the light pole base extends into the ground.

A plurality of bolts 20 are embedded in a top 21 of the light pole base15 for attaching a lower end 22 of the light pole 16 to the base 15. Alower end 22 of the light pole 16 will have a pattern of holes forreceiving the bolts 20. The number and orientation of the bolts 20 willbe determined by the hole pattern in the lower end 22. Smaller lightpoles 16 may require only three mounting bolts 20 of a relativelysmaller diameter to secure the light pole 16 to the base 15, while alarger light pole 16 may require four or more larger diameter mountingbolts 20 to provide sufficient strength. Nuts 23 are attached to thebolts 20 to secure the light pole 16 to the base 15.

The prior art cylindrical cast concrete light pole base 15 may beassembled from two or more form sections 26 of the type shown in FIG. 2.Each form section 26 has a curved interior wall 27 which forms part of acavity in which the light pole base 15 is cast. Each form sections 26has a vertical side flange 28 which is shown having a plurality spacedbolt holes 29. The flanges 28 on two of the form sections 26 are bolted,clamped or otherwise secured together to define a cylindrical cavity inwhich the light pole base 15 is cast. The form sections 26 also mayinclude a curved upper flange 30 extending outwardly along a curved topedge 31 of the section 26 and a corresponding curved lower flange (notshown) extending outwardly along a curved lower edge 32 of the sections26. The form sections 26 may be provided in different lengths forforming different length light pole bases. For example, a light polebase manufacturer may have pairs of sections 26 in 4 foot, 8 foot and 12foot lengths. Two 4 foot sections, for example, may be bolted togetherwith two 12 foot sections for manufacturing a 16 foot light pole base.

The visible portion of the above described prior art light pole basesare functional, but not very attractive. For upscale installations, itwould be desirable to have a more attractive light pole base, forexample, one having the appearance of stacked natural stone blocks,bricks, or another pleasing appearance. According to the presentinvention, a form is provided for casting the visible above groundportion of a light pole base. FIG. 3 is a perspective view showing aexemplary light pole base 35 cast according to the present invention.The light pole base 35 has a cylindrical lower portion 36 which, in use,will be embedded in the ground during use and has a textured upperportion 37 which will extend above the ground surface. In theillustrated embodiment, the upper portion 37 is generally square whenviewed from the top and has the appearance of a stack of irregularshaped stone blocks 38 and a simulated stone top cap 39 with simulatedmortar joints between the blocks 38 and between the blocks 38 and thetop cap 39. However, it will be appreciated that the upper portion 37may be rounded and may have different appearances other than blocks. Oneor more conduits (not shown) are embedded in the pole base to connectone or more openings 40 in the lower portion 36 with one or moreopenings 41 (FIGS. 5 and 6) near the top center of the top cap 39 forfeeding electrical wires from underground conduits (not shown) to alighting fixture mounted on a light pole supported on the base 35.

During manufacture, the light pole base 35 is cast upside down in aform, with the cap 39 located at the bottom of the form. FIGS. 3 and 4show a bottom 42 of the lower base portion 36. Preferably, an optionalhook 43 is shown embedded in the bottom 42 of the lower portion 36 toextend in a recess 44. The hook 43 provides a point for lifting theinverted light pole base 35 from the form in which it was cast after theconcrete has sufficiently cured. The hook 43 may be formed, for example,from a bent section of rebar embedded in the concrete.

The cap 39 at the top of the light pole base 35 is specificallyconfigured for the mounting requirements of a specific light pole (notshown) which will be mounted on the base 35. FIG. 5 shows an exemplarytop cap 39 which preferably has a slightly raised center portion 45where a large light pole will be mounted. When a raised center portion45 is provided, it will reduce the likelihood of water on the cap 39from seeping between the light pole and the cap 39 and entering thewiring conduit openings 41. The illustrated center portion 45 isoctagonal. However, other shapes may be provided, if desired. Threadedends of 4 bolts 46 which are embedded in the upper portion 37 extendfrom the cap 39 for securing a light pole to the base 35. The size andspacing and number of bolts 46 will be determined by the hole size andspacing on a base of the light pole. The number, size and configurationof the bolts will vary between different light pole manufacturers andbetween different light pole models made by each manufacturer. For largelight poles, for example, one inch bolts may be used while smaller lightpoles may only need ¾ inch bolts. The number and location of wiringconduit openings 40 and 41 in the base also will be determined by thewiring layout for the light pole and for nearby light poles connected tothe same electrical circuit.

FIG. 6 shows an exemplary smaller raised center portion 45′ on a basecap 39′, with a different pattern of smaller bolts 46′ and with fourconduit openings 41′. The center portion 45′ shown in FIG. 6 is smallerthan in FIG. 5 and is configured for mounting a smaller light pole thanthe center portion 45 of FIG. 5. Here the bolts 46′ may, for example,have a ¾ inch diameter. It should be noted that in each case, the boltsize is based on the light pole manufacturer's specifications for thepole which will be mounted on the base. The illustrated conduit openings41′ are shown having different diameters based on the number and size ofwires which will be passed through each conduit.

FIG. 7 shows an open form 50 according to one embodiment of theinvention for casting the textured upper portion 37 of a light pole base35. A textured polyethylene mat 51 is supported on a steel base 52. Themat 51 imparts a desired texture to an upper surface of the light poletop cap 39. In the illustrated embodiment, two polyethylene moldsections 53 and 54 are provided for defining the sides of the upperportion of the light pole base. The two mold sections 53 and 54 aresupported, respectively, by two steel jackets 55 and 56 which aresupported on the base 52. It should be appreciated that more than twomold sections and steel jackets may be used to form the mold cavity. InFIG. 7, the mold sections and steel jackets are shown in an openposition which allows removal of a cured concrete light pole base fromthe form 50. When mold sections 53 and 54 and the steel jackets 55 and56 are moved to a closed position and secured together with bolts orclamps, they define a mold cavity in which the sides are formed by thetextured surfaces of the mold sections 53 and 54 and the cavity bottomis formed by the mat 51 and an insert 57. When in the closed position,the steel jackets 55 and 56 are secured to the base plate 52 to maintainalignment with the mat 51 and for stability.

When casting a concrete light pole base, one or more pairs of thecylindrical form sections 26 are stacked above the form 50 to form thecylindrical lower portion 36 of the light pole base 35. Adjacent formssections are secured together, for example, with bolts or with clamps.

In the illustrated embodiment of the form 50, one half of the cavity ofthe upper portion of the light pole base is defined by the mold section53 and the other half is defined by the mold section 54. When the upperportion of the light pole base has a generally square cross section,each mold section will form two sides of the upper portion. It will beappreciated that the mold cavity may be formed by more than two moldsections, such as a separate section forming each side of the upperportion of the light pole base. It also will be appreciated thatalthough the mold sections 53 and 54 are illustrated for shapingsimulated stacked stone blocks covered by a top block, the mold sectionsmay be configured to impart any desired decorative appearance to theupper portion of the light pole base.

According to one feature of the form 50, an insert 57 is shownpositioned in an opening 58 located in the center of the mat 51 and thebase 52. Different configured inserts 57 can be positioned in the matand base opening to extend either slightly below the textured surface ofthe mat 51 at the opening 58 or flush with the textured surface.Preferably, the insert 57 and the mat 51 are formed from a tough,resilient material, such as a polyurethane. The central opening 58preferably has shaped sides which allow aligning the insert 57 in themold cavity. In the illustration, the central opening 58 has anoctagonal shape. However, it should be appreciated that other shapes maybe used. When the upper surface of the insert 57 is slightly recessedbelow the upper surface of the mat 51, it will form a slightly raisedsurface on the top center of the cast cap 39 in the area where the lightpole is mounted on the light pole base. This reduces the risk of waterflowing into the conduit openings on the light pole base.

An insert 59 shown in FIG. 8 has openings 61 in which threaded ends ofbolts 60 are positioned and frictionally held. The bolts 60 are firmlyheld in a desired position to extend into a mold cavity above the insert59 for embedding in a cast concrete light pole base. By snugly holdingthe threaded ends of the threaded bolt ends in the insert 59, thethreads will not be contaminated with cement when a light pole base iscast in the form. The bolt holes are located to correspond to the bolthole spacing and pattern on a light pole which will be mounted on thebase. Preferably, the insert 59 will have a number of bolt holes forarranging the bolts in different patterns according to the requirementsfor different light poles. The unused bolt holes in the insert are filedwith removable plugs when casting a light pole base. Thus, the number ofbolts, the size of the bolts and the spacing of the bolts can be quicklychanged when casting light pole bases for use with different configuredlight poles. It should be appreciated that the insert 59 may be formedfrom, for example, a tough, resilient material such as polyurethane sothat it can be removed intact from a cast light pole base for reuse, ormay be formed from a disposable material intended for a single use.

Threaded ends of the bolts 60 which will project from the top of thelight pole base are retained in the insert 59 while the light pole baseis cast. The insert 59 has sufficient depth to protect the threaded endsfrom the concrete during casting of the base. If desired, the threadedends may be coated with a grease or lubricant which will facilitatepushing the threaded ends into the insert and also prevent concrete fromadhering to the threads. When a cast concrete light pole base is liftedfrom the form in which it was cast, the insert 57 will remain on theprojecting threaded bolt ends. The insert 57 will protect the threadedbolt ends until it is removed from the light pole base. Typically, theinverted cast light pole base will be lifted from the open form usingthe embedded hook 43 in the bottom 42, and the light pole base will belaid on its side. The insert 57 will then be pulled from the threadedbolt ends which project from the top of the light pole base. A plate(not shown) with a hook on it may be secured to the threaded boltsprojecting from the top of the light pole base for lifting the lightpole base and lowering the light pole base into a cylindrical hole inthe ground.

When a cast light pole base is withdrawn from the mold cavity and theinsert 59 is separated from the light pole base the threaded bolts 60extend above the top of the light pole base in a pattern configured toreceive and secure the base of a light pole. The ends of the bolts 60visible in FIG. 8 extend into the mold cavity for embedding the bolts 60in the concrete light pole base. To provide a sufficient length forsecuring large light poles to the base, the bolts 60 may extend somedistance into the base and may have hooked or other shaped ends forsecurely anchoring the bolts in the hardened concrete.

FIG. 8 shows details of the base 52, the mat 51, the opening 58 in themat 51 and the insert 59. It will be seen that the thickness of theinsert 59 is sufficient to completely enclose the threaded end portionsof the bolts 60 which will extend above the top of the cast concretelight pole base. The opening 58 may have a depth so that a top surface68 on the insert 59 is either flush with a top surface on the mat 51, oris recessed slightly below the top surface. When the surface 68 isrecessed below the mat surface, the center portion 45 on the top cap 39be raised above the upper surface of the top cap 39. When the surfacesare flush, the center portion 45 on the light pole base will be flushwith the upper surface of the top cap 39.

FIGS. 8 and 9 show holes 62 in the insert 59 for positioning wiringconduits in the cast light pole base. The wiring conduits (not shown)may be, for example, of plastic or of aluminum. An end of a wiringconduits may be inserted into the holes 62, or a bushing 64 may beinserted into each hole 62. The bushing 64 has a tapered projecting end65, as seen in FIG. 9. An end of the conduit 63 is inserted over andseated on the bushing end 65 to form a seal while the light pole baseconcrete hardens. When the insert 59 is separated from the cast lightpole base, the bushing 64 will pull free from the conduit end 66,leaving a wiring opening flush with the top of the light pole base.Alternately, a rod (not shown) may be positioned in each hole 62 and abushing 64 may be positioned on the rod. Any unused holes 62 in theinsert 59 are plugged when casting a light pole base. A similar bushingis attached to the inside of a form which casts the lower portion of thelight pole base for positioning a lower end of the conduit to form thelower conduit openings 40 of FIG. 3.

When the light pole base is used with smaller light poles, the centerportion 45 may be smaller to fit with a smaller base on the light pole.As shown in FIG. 10, an adapter 67 may be placed in the opening 58 forreceiving a smaller size insert (not shown). Preferably, the adapter 67will be flush with the mat 51. The top surface of the insert also may beflush with the adapter 67 and the mat 51 or may be recessed forproviding a raised surface for mounting the light pole.

The cylindrical lower portion 11 of the light pole base 10 which isburied in the ground may be formed with conventional forms of the typeshown in FIG. 2 used for casting cylindrical light pole bases. Theseforms are mounted on top of the closed form 50 to extend above thecavity formed by the mold sections 53 and 54. Typical forms aresemicircular elongated shells which are secured together while theconcrete light pole base is cast and cures, and are separated from thecast light pole base before opening the form. The shells may have asufficient length to cast a light pole base having the desired lengthlower portion 11, or two or more shells may be stacked to achieve thedesired length. It will be noted that the minimum length of the lowerportion will be determined by the configuration of the light pole andthe soil conditions to provide a stable base for the light pole.

FIG. 11 shows a modified embodiment for casting a concrete light polebase. A base 74 and mat 75 are similar to the previously described baseand mat. A resilient insert 76 located in an opening in the base 74 andmat 75 extends flush with the top of the mat 75. The insert is providedwith several sets of holes for positioning bolts 77 in differentconfigurations for mounting different configured light poles on a castlight pole base and for different conduit configurations. A polyurethanecover 78 is placed over the insert and is sized to shape the top ofsurface of the light pole base. The cover 78 is provided with bolt holes79 and conduit positioning holes 80 which align with specific holes inthe insert 76. The cover 78 covers all holes in the insert 76 which arenot required for the light pole base being cast. Different covers 78 areprovided to accommodate the hole requirements for mounting differentlight poles. Depending on the light pole mounting configuration, a cover78 is selected.

A section 81 of a form for defining a portion of the upper portion ofthe light pole base is shown having a cylindrical interior 82 forcasting a cylindrical upper portion. The interior is illustrated ashaving vertical flat areas for simulating vertical boards on the exposedupper portion of the cast concrete light pole base. So long as the formconfiguration provides sufficient relief so that it can be easilyseparated from the hardened concrete, the interior 82 may be made ofsteel or another hard material. However, if the textured upper surfacewill have areas which will not release from a hard form, the texturemust be created in a resilient liner, for example, a polyurethane liner,which will release from the hardened concrete.

It will be appreciated that various modifications and changes may bemade to the above described preferred embodiments of a form for castingconcrete light pole bases without departing from the scope of thefollowing claims.

The invention claimed is:
 1. A process for casting a concrete light polebase comprising the steps of: a) providing a rigid base having anopening in an upper surface; b) providing an insert positioned in thebase opening, said insert having a plurality of bolt openings shaped toreceive threaded ends of bolts, wherein the bolt openings are arrangedto position the threaded ends of bolts for securing to a light pole, andwherein said insert has an opening for positioning an end of a wireconduit in a cast light pole base; c) positioning the threaded ends ofbolts in the bolt openings with the bolts having ends extending upwardlyfrom the insert; d) positioning a form on the rigid base, said form andsaid rigid base defining a cavity enclosing the extended portion of thebolts for casting at least a portion of a light pole base which will bevisible during use of the light pole base, wherein said opening in therigid base has shaped sides which align the insert in the cavity; and e)casting a light pole base in said form.
 2. A process for casting aconcrete light pole base, as set forth in claim 1, and further includingthe step of providing a plurality of inserts with different openingpatterns for orienting bolts and at least one wiring conduit fordifferent configured light poles; and wherein an insert having anopening pattern for a specific light pole is selected and positioned inthe base opening.
 3. A process for casting a concrete light pole base,as set forth in claim 2, wherein the rigid base is provided with aresilient mat covering an upper surface of the rigid base, saidresilient mat having an opening aligned with the rigid base opening, andwherein the form is positioned on the resilient mat.
 4. A process forcasting a concrete light pole base, as set forth in claim 3, theresilient mat is provided with a textured upper surface for imparting atexture to a top of the cast light pole base, and wherein the insert isrecessed below the textured upper surface of the resilient mat.
 5. Aprocess for casting a concrete light pole base, as set forth in claim 1,and wherein said insert is provided with multiple sets of bolt openingsarranged to position bolts for different configured light poles and aplurality of different conduit openings, wherein bolts are positioned ona set of bolt openings for a specific light fixture; and furthercomprising the step of plugging any bolt and conduit openings which arenot needed for the specific light fixture.
 6. A process for casting aconcrete light pole base, as set forth in claim 5, and wherein saidinsert is provided with multiple sets of bolt openings arranged toposition bolts for different configured light poles and a plurality ofdifferent conduit openings, wherein bolts are positioned on a set ofbolt openings for a specific light fixture; and further comprising thestep of covering any bolt and conduit openings which are not needed forthe specific light fixture.
 7. A process for casting a concrete lightpole base, as set forth in claim 1, and wherein said insert is providedwith multiple sets of bolt openings arranged to position bolts fordifferent configured light poles and a plurality of different conduitopenings, wherein bolts are positioned on a set of bolt openings for aspecific light fixture; and further comprising the step of covering anybolt and conduit openings which are not needed for the specific lightfixture.
 8. A process for casting a concrete light pole base, as setforth in claim 1, and wherein the form positioned on the base comprisesa lower section for casting an upper portion of the light pole base castin the form and an upper section for casting a lower portion of thelight pole base cast in the form, and wherein the lower form section hasa decorative interior cavity wall adapted to produce a decorativeappearance on the exterior of the upper pole base portion.
 9. A processfor casting a concrete light pole base, as set forth in claim 8, andwherein the decorative cavity wall on the lower form produces anappearance of stacked stone blocks and a top cap on the upper pole base.10. A process for casting a concrete base comprising the steps of: a)providing a rigid base having an opening in an upper surface; b)providing an insert positioned in the base opening, said insert having aplurality of bolt openings shaped to receive threaded ends of bolts, andwherein the bolt openings are arranged to position the threaded ends ofbolts; c) positioning the threaded ends of bolts in the bolt openingswith the bolts having ends extending upwardly from the insert; d)positioning a form on the rigid base, said form and said rigid basedefining a cavity enclosing the extended portion of the bolts forcasting at least a portion of a base which will be visible during use ofthe base, wherein said opening in the rigid base has shaped sides whichalign the insert in the cavity; and e) casting a base in said form.